Performance Evaluation of Concrete Paver Blocks with Partial Replacement of Fine Aggregate by Waste Foundry Sand

Abstract

The construction industry is increasingly focusing on sustainable alternatives to natural construction materials due to rapid depletion of natural resources and rising environmental concerns. Waste Foundry Sand (WFS), generated as a by-product of metal casting industries, possesses physical characteristics similar to conventional fine aggregates and offers significant potential for utilization in concrete products. This study investigates the performance of M30 grade concrete paver blocks incorporating Waste Foundry Sand as a partial replacement of fine aggregate at replacement levels of 10%, 15%, 20%, 25% and 30%. The physical properties of Waste Foundry Sand and crushed sand were evaluated through specific gravity, fineness modulus, and water absorption tests. Concrete paver blocks were cast, cured for 28 days, and tested for compressive strength, water absorption, abrasion resistance, and flexural strength in accordance with relevant Indian Standards. The results demonstrated that the incorporation of Waste Foundry Sand significantly influences the mechanical and durability characteristics of paver blocks. Among the investigated mixes, the 10% WFS replacement level exhibited the best overall performance, achieving a compressive strength of 40.55 MPa, flexural strength of 3.26 MPa, water absorption of 5.31% and satisfactory abrasion resistance within the limits prescribed by IS 15658:2021. The study confirms that Waste Foundry Sand can be effectively utilized as a sustainable partial replacement of natural fine aggregate in concrete paver block production, contributing to environmental conservation, reduction in industrial waste disposal and economic benefits in construction practices.

Introduction

The text presents a study on the utilization of Waste Foundry Sand (WFS) as a partial replacement for fine aggregate in M30 grade concrete paver blocks. The aim is to reduce the depletion of natural sand resources, manage industrial waste, and develop sustainable construction materials.

Background and Motivation

Concrete paver blocks are widely used in pavements, footpaths, parking areas, and infrastructure projects because of their strength and durability. However, increasing construction demand has caused excessive consumption of natural fine aggregates, creating environmental concerns.

Waste Foundry Sand (WFS), a by-product of the metal casting industry, is generated in large quantities and often disposed of in landfills. Using WFS in concrete paver blocks provides benefits such as:

• Reduction in industrial waste disposal
• Conservation of natural sand resources
• Lower construction material cost
• Promotion of sustainable construction practices

Research Objective

The study investigates the effect of replacing crushed sand with different percentages of WFS in M30 concrete paver blocks.

Replacement levels studied:

• 10%
• 15%
• 20%
• 25%
• 30%

The performance was evaluated using:

• Compressive strength test
• Water absorption test
• Flexural strength test
• Abrasion resistance test

Literature Findings

Previous studies showed that WFS can be successfully used in:

• Bricks
• Masonry units
• Concrete products

However, limited research existed on WFS-based M30 grade concrete paver blocks, especially regarding combined strength and durability performance.

Methodology

Concrete paver blocks of size 250 mm × 130 mm × 60 mm were prepared using M30 grade concrete mix.

Procedure:

1. Replace crushed sand with WFS at different percentages.
2. Cast paver blocks.
3. Cure specimens in water for 28 days.
4. Perform mechanical and durability tests.

Material Properties

Comparison of materials:

Test Results

1. Compressive Strength

• Maximum strength obtained at 10% WFS replacement
• Strength achieved: 40.55 MPa

Strength values:

• 10% → 40.55 MPa
• 15% → 36.93 MPa
• 20% → 38.58 MPa
• 25% → 38.75 MPa
• 30% → 37.59 MPa

2. Water Absorption

• All mixes satisfied the IS 15658:2021 limit of less than 6%.
• Absorption increased slightly with higher WFS content.

Values:

• 10% → 5.31%
• 30% → 5.88%

3. Flexural Strength

• Highest flexural strength occurred at 10% WFS replacement
• Value: 3.26 MPa

Strength gradually decreased with higher WFS percentages.

Conclusion

On the basis of detailed investigation and studies and results obtained, it is concluded that 1) 10% Waste Foundry Sand replacement was identified as the optimum mix based on combined mechanical and durability performance. 2) Utilization of Waste Foundry Sand can be contributed to sustainable construction practices and can also reduces dependency on natural fine aggregate. 3) Waste Foundry Sand shall provide economic benefits through reduction in the material costs and shall provide solution for industrial waste disposal. 4) The present investigation recommends 10% Waste Foundry Sand replacement as the optimum proportion for M30 grade concrete paver block production. 5) Thus, Waste Foundry Sand can be successfully utilised as a partial replacement of aggregate in concrete paver block.

References

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Copyright

Copyright © 2026 K T Patil, R S Datir, A V Avhad, A D Bhoj. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.